PI's ThermaCell Refillable Cartridges

[pureinsanity]

I know lots of avid bow hunters use thermacells, myself included. I thought I would share this with you fellow bow hunters!

This is just an alternate method to shacks thermacell refill 101.

Butane is highly flammable and if you do not feel comfortable then please do not attempt this modification. Do not attempt unless you are in a well ventillated area with no open flame.

You can make this modification with basic house hold tools. Get creative and you will make it work.

We will start with finding a valve to stick into the bottom of your thermacell cartridge. I went to the dollar store and picked up two different kinds of refillable grill lighters.

Start by removing the screws and splitting them open. A little tip, there is a plastic piece at the start of the chrome shaft. Slide that off and they will open easier. Or if you are like me you are just throwing them away after you get the part you need out of it anyway.

The ignitor looks like the picture below. There is a rubber or plastic piece that you should remove and save for later. you will see why at the end of this tutorial.

Remove the butane cartridge (looks like a lighter) now you need to remove the butane (unless you have an empty one laying around) Be sure to put on your safety goggles and make sure you are away from an open flame. Gasses are going to be released.

There is an adjustment on the top of the lighter to make the flame bigger or smaller. Start to unscrew that. Eventually you will hear air come out and then so will butane. This can get very cold so do not let it touch your skin.

Once all the butane I will look at the underside of the lighter. You will see a valve at the bottom. In most cases the valve is formed into plastic, and then that plastic piece is formed into another piece of plastic and then into the lighter.

We are after that valve formed in plastic. It is very important you do not damage the plastic the valve is in or you will have to start all over. I will start by smashing the lighter with a hammer towards the top to get access to the bottom of the lighter.

Now take a snips or pliers of some sort and start clipping away the plastic piece to get to the valves. Don't forget your safety glasses as pieces start to fly all over the place

Clean it up a little bit and you have your valves!

[pureinsanity]

Now grab your empty ThermaCell Cartridge. On the bottom of the cartridge is a slot. In that slot is a BB. Use something hard to push that BB into the cartridge. I used a pick and that worked well. This will release all the pressure in the cartridge.

I will then find a drill bit that is close to the size of my valves I am going to be installing. I will drill a hold in the bottom of the cartridge.

Now its time to shake the BB out of the cartridge and as much of the plastic debris as you can. A magnet on a metal object will help get the bb out easier, but usually a few good shakes will get everything out.

Now I will test to see if my valves fit in the hole I drilled.

Yup fits good! For the other valve that was a bit bigger I had to use a reamer to make the hole a tad bigger.

Now that my valves fit it is time for some epoxy! I will mix up a 2 part epoxy that adheres to several surfaces. The particular brand I am using is Locktite 5 minute epoxy. It sets up in 5 minutes, dry in 20 minutes, and full cure in 24 hours. I am able to fill them after the 20 minutes is up with no leaks. Make sure you mix your epoxy slowly for about a minute to avoid air bubbles and possible leaks. But remember its a 5 minute epoxy so stir to long and it might harden before you even get it on your thermacell cartridge.

Now I spread a small amount on the outside of the valve being very careful not to get any in the valve! Doing this will ensure a better seal between the valve and the cartridge.

Next I will insert the valve into the cartridge making sure its tight and I will then add epoxy to the bottom of the cartridge to ensure a good solid bond with no leaks.

Sit back and relax or start working on another refill while you let them set up. 20 minutes later, or 24 hours later if you want it to fully cure first you will have a refill ready thermacell cartridge.

Ready to refill with MINIMUM butane loss. When filling you sometimes have to stop and depress the brass valve to let some pressure out.

[pureinsanity]

After refilling just to check if you have a leak, mark on your bottle where you refilled too and then check it in the morning to see if you have any leaks.

Now remember I told you to take the rubber or plastic piece on the ignitor off?

Here is why. With a little bit of trimming you can add a protector so your valve doesn't get damaged or depressed releasing your butane.

There you go! Now there is no need for messing with the soft brass fitting, using adapters which make you lose lots of butane. Also, if you fill up the cartridge full you get approximately 1 fluid ounce of butane. where when we buy them they only contain .78 ounces.

Good luck and do at your own risk.

[killerelement]

nice instructions

[musky hunter]

Very ingenious and I'm impressed with yhour mechanical skills. But as an engineer, I know that most expoxies don't hold well on plastics. I'd be concerned about a possible failure of the expoxy joint holding the valve in. While I can't identify the plastic used from the photos, all the common l plastics, nylon, UHMW, delrin, and all the polyethelynes just don't take well to expoxied joints. I know, I've searched and have not found an epoxy that holds well on plastic and those that do have some adhesion strenght are normally only available through distributors not normally available to the general public. So, if you do this, please, do not smoke!

[harvey lee]

Great job on the refill canisters.

Now, what do you use for pads?

[pureinsanity]

Very ingenious and I'm impressed with yhour mechanical skills. But as an engineer, I know that most expoxies don't hold well on plastics. I'd be concerned about a possible failure of the expoxy joint holding the valve in. While I can't identify the plastic used from the photos, all the common l plastics, nylon, UHMW, delrin, and all the polyethelynes just don't take well to expoxied joints. I know, I've searched and have not found an epoxy that holds well on plastic and those that do have some adhesion strenght are normally only available through distributors not normally available to the general public. So, if you do this, please, do not smoke!

I was questioning the epoxy myself but this stuff holds very well. I originally made one with a brass fitting and it took me almost 20 minutes to just remove the brass fitting and another 15 or so to remove all the epoxy. One thing I forgot to mention was I scuffed the plastic with scotch brite pads to have a better hold.

I have had several of these laying around in my basement for a few weeks now and the bond is still strong. Also have had one in my car in the elements of heat and humidity and it still has not gave way.

But I do agree, do with caution and do not do this by an open flame.